Secondary Battery Head Cover Assembly Space Optimization
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Solution Overview
Problem
The existing secondary battery assembly methods require protrusions that occupy internal space, complicating the assembly process and reducing battery capacity due to the need for a top bracket and lower plastic protrusions.
Innovation Solution
A secondary battery head cover assembly that integrates a top connection sheet with two naked battery core insulation sheets, eliminating the need for a top bracket by using a head cover with an electrode pole through hole and connecting pieces, and wrapping the battery core with insulation sheets that cover side and bottom surfaces, allowing for a more compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a top bracket and lower plastic protrusions are used to connect the head cover, then the connection structure is achieved, but internal space is occupied and assembly complexity increases
Solution Approach 1:
The patent merges the top bracket and lower plastic into an integrated connection structure where the head cover directly integrates both connection functions. The head cover includes a first connection portion extending from the first electrode pole and a second connection portion extending from the second electrode pole, eliminating the need for separate top bracket and lower plastic components. This integration reduces part count and assembly complexity while maximizing internal space.
Solution Approach 2:
The head cover is designed to perform multiple functions simultaneously: it serves as the protective cover, the connection structure for both electrodes, and the mounting structure for the insulation sheet. The first and second connection portions of the head cover directly connect to the first and second electrodes respectively, while also providing attachment points for the insulation sheet, thereby eliminating the need for dedicated top bracket and lower plastic components.
2Strength
If protrusions are provided for connection, then structural connection is achieved, but battery capacity is reduced due to space occupation
Solution Approach 1:
The patent combines the connection function into the head cover itself, eliminating separate protruding components. The first connection portion and second connection portion are integral parts of the head cover, providing strong electrical connections while minimizing space occupation. This integration ensures that connection strength is maintained through direct bonding or welding of the connection portions to the electrodes, without requiring additional protruding structures that would reduce battery capacity.
3Reliability
If top bracket and lower plastic are used, then connection structure is formed, but assembly process is complicated
Solution Approach 1:
The patent integrates the top bracket and lower plastic functions into the head cover, reducing the number of components from three (head cover, top bracket, lower plastic) to one (head cover with integrated connection portions). This simplification directly reduces assembly steps and manufacturing complexity while maintaining connection reliability through the direct integration of connection portions that are bonded or welded to the electrodes in fewer steps.
Solution Approach 2:
The head cover is pre-formed with the first and second connection portions integrated into its structure before assembly. This preliminary formation of the connection structure eliminates the need for separate installation steps for top bracket and lower plastic, streamlining the assembly process while ensuring reliable connections are established in a single assembly operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution saves internal space, improving energy density by eliminating the need for protrusions and enhancing the assembly process efficiency.
Implementation Method 1
the top connection sheet and the lower plastic are integrated as a whole, and the top connection sheet is hot-melt connected with the top bracket and the lower plastic
Data Source
AI summary
The present application relates to a secondary battery head cover assembly, a secondary battery including the same and an assembling method thereof. The secondary battery head cover assembly includes a head cover and an insulation structure, the insulation structure includes a top connection sheet and two naked battery core insulation sheets, an electrode pole is provided on the head cover, and an electrode pole through hole, through which the electrode pole passes, is provided at a position on the top connection sheet corresponding to the electrode pole, the top connection sheet is located below the head cover and is fixed to the head cover. The secondary battery includes the secondary battery head cover assembly and the naked battery core, the naked battery core is located below the top connection sheet, and the two naked battery core insulation sheets wrap the side and bottom surfaces of the naked battery core.